Motor stator with loose laminations

Abstract

A motor stator is constructed from loose laminations which are aligned and secured to the compressor housing at the time of assembling the compressor unit. The loose lamination stator is first attached to the compressor housing to initially locate the stator. A solid sizing mandrel is pushed through the rotor accommodating bore to remove any burrs and initially size the bore. An expanding mandrel is then positioned within the rotor accommodating bore and expanded to finalize the sizing of the bore and the alignment with the compressor housing. Once the final size and alignment have been achieved, the stator is secured to the motor housing.

What is claimed is:  
     
       1. A method of assembling a motor stator having an inner surface defining a rotor bore to a housing, said method comprising: 
       positioning said motor stator on said housing;  
       inserting a non-adjustable mandrel within said rotor bore, an outer surface of said non-adjustable mandrel engaging said inner surface of said motor stator which defines said rotor bore;  
       removing said non-adjustable mandrel from said rotor bore;  
       inserting an expandable mandrel within said rotor bore;  
       expanding said expandable mandrel within said rotor bore;  
       securing said motor stator to said housing.  
     
     
       2. A method of assembling a motor stator having a rotor bore to a housing, said method comprising: 
       positioning said motor stator on said housing;  
       inserting a non-adjustable mandrel within said rotor bore;  
       removing said non-adjustable mandrel from said rotor bore;  
       inserting an expandable mandrel within said rotor bore;  
       expanding said expandable mandrel within said rotor bore;  
       securing said motor stator to said housing;  
       wherein said housing includes a crankshaft bore and a crankshaft extending through said crankshaft bore and into said rotor bore, and said step of positioning said motor stator on said housing includes inserting a dummy rotor into said rotor bore to engage said crankshaft.  
     
     
       3. A method of assembling a motor stator having a rotor bore to a housing, said method comprising: 
       positioning said motor stator on said housing;  
       inserting a non-adjustable mandrel within said rotor bore;  
       removing said non-adjustable mandrel from said rotor bore;  
       inserting an expandable mandrel within said rotor bore;  
       expanding said expandable mandrel within said rotor bore;  
       securing said motor stator to said housing;  
       wherein said housing includes a crankshaft bore and a crankshaft extending through said crankshaft bore and into said rotor bore, and said step of inserting said non-adjustable mandrel within said rotor bore includes engaging said crankshaft with said non-adjustable mandrel.  
     
     
       4. A method of assembling a motor stator having a rotor bore to a housing, said method comprising: 
       positioning said motor stator on said housing;  
       inserting a non-adjustable mandrel within said rotor bore;  
       removing said non-adjustable mandrel from said rotor bore;  
       inserting an expandable mandrel within said rotor bore;  
       expanding said expandable mandrel within said rotor bore;  
       securing said motor stator to said housing;  
       wherein said housing includes a crankshaft bore and a crankshaft extending through said crankshaft bore and into said rotor bore, and said step of inserting said expandable mandrel within said rotor bore includes engaging said crankshaft with said expandable mandrel.  
     
     
       5. A method of assembling a motor stator having a rotor bore to a housing, said method comprising: 
       positioning said motor stator on said housing;  
       inserting a non-adjustable mandrel within said rotor bore;  
       removing said non-adjustable mandrel from said rotor bore;  
       inserting an expandable mandrel within said rotor bore;  
       expanding said expandable mandrel within said rotor bore;  
       securing said motor stator to said housing;  
       wherein said step of positioning said motor stator on said housing includes inserting a dummy rotor into said rotor bore.  
     
     
       6. The method according to  claim 1 , further comprising the step of collapsing said expandable mandrel prior to securing said motor stator to said housing. 
     
     
       7. The method according to  claim 6 , further comprising the step of re-expanding said expandable mandrel after collapsing said expandable mandrel and prior to securing said motor stator to said housing. 
     
     
       8. The method according to  claim 1 , wherein said motor stator comprises a plurality of loose laminations and said step of inserting said non-adjustable mandrel includes the step of aligning said plurality of loose laminations. 
     
     
       9. The method according to  claim 8 , wherein the step of inserting said non-adjustable mandrel includes the step of deburring said rotor bore. 
     
     
       10. A method of assembling a motor stator having a rotor bore to a housing, said method comprising: 
       positioning said motor stator on said housing;  
       inserting a non-adjustable mandrel within said rotor bore;  
       removing said non-adjustable mandrel from said rotor bore;  
       inserting an expandable mandrel within said rotor bore;  
       expanding said expandable mandrel within said rotor bore;  
       securing said motor stator to said housing;  
       wherein the step of inserting said non-adjustable mandrel includes the step of deburring said rotor bore.  
     
     
       11. The method according to  claim 1 , wherein the step of expanding said expandable mandrel includes the step of sizing said rotor bore. 
     
     
       12. The method according to  claim 1 , further comprising the step of stacking a plurality of loose laminations to create said motor stator. 
     
     
       13. The method according to  claim 12 , wherein the step of stacking said plurality of loose laminations includes stacking a plurality of groups of laminations with each group being circumferentially orientated with respect to an adjacent group. 
     
     
       14. The method according to  claim 13 , wherein the step of stacking a plurality of groups of laminations comprises stacking four groups of laminations each orientated 180° with respect to said adjacent group.